Decoupled and Modular Multi Channel Order Fulfillment System with Control System Adaptable for Demand-Driven Flexibility and Productivity

The present invention is directed to a configurable order fulfillment and control system in a warehouse environment, and in particular to dynamically managing the warehouse environment and the order fulfillment process during changing demand needs by providing a decoupled and modular fulfillment system.

The control of an order fulfillment system within a warehouse facility with a variety of workers or agents (e.g., human pickers, robotic pickers, item carrying vehicles, conveyors, and other components of the order picking system) is a complex task. Conventional control methods are used to seek various objectives in an ever-increasingly complex order fulfillment environment characterized by scale of SKU variety, order composition ranging from single SKU to multiple SKUs, widely varying order demand in magnitude and time scales coupled with the very demanding constriction of delivery deadline. This complexity is further compounded as conventional warehouse environments traditionally rely on “set in stone” automated and manual hardware and processes where the warehouse environment may be able to handle current day-to-day order fulfillment operations but are locked down in turns of upgradability and flexibility in the face of rapidly changing demands and needs.

Embodiments of the present invention provide methods and a system for a decoupled and modular order-fulfillment system with intelligently orchestrated and dynamic workflows for demand-driven flexibility and productivity. Such order-fulfillment systems may be utilized in a variety of different environments, e.g., an e-commerce fulfillment center, a warehouse, and a micro-fulfillment center. Exemplary embodiments are configured to dynamically change how orders are fulfilled in/near real-time based on, for example, customer demands, available resources, and resource optimization via intelligent orchestration to flexibly adapt a dynamic reconfigurable physical infrastructure and associated workflows in response to changing needs. Such dynamic reconfigurability includes, for example, flexibly adding or reducing order fulfillment capacity (e.g., reconfigurable workstations, additional inventory storage, human or robot workers, and flexible automation and control solutions) temporarily or permanently, and adapting the capabilities over time allowing for flexible modular up/down-scaling. An exemplary embodiment and method for multi-channel order-fulfillment includes a combination of fixed automation, flexible mobile automation, and modular process/control systems. Exemplary fixed automation includes automated storage and retrieval systems (AS/RS storage systems) and unit sortation systems (e.g., cross-belt sorter, sorting mezzanines, and Bombay-style sorters). Exemplary mobile automation includes bin transportation by Autonomous Mobile Robots (AMRs), for example, bin-to-person AMRs, sortation inventory routing AMRs, and customer designated solutions (e.g., shelf-to-person AMRs). Exemplary modular process/control systems include a dynamically reconfigurable warehouse controller, control system, or orchestrator, a fulfillment control and monitoring system, a warehouse management system (WMS), a warehouse execution system (WES), and a supply chain management system.

An order-fulfillment system for a warehouse in accordance with the present invention includes a control system, memory, a modular inventory storage system, and reconfigurable workstations that may be operationally reconfigured, with the control system operable to revise fulfillment operations using the altered system without having to be re-programmed. The control system controls fulfillment activities of the warehouse, manages the configuration of workstations for order fulfillment, inventory induction, or order packing operations, and records operational data corresponding to the fulfillment activities in the warehouse. The control system comprises a plurality of workflows selected from a workflow library. The memory holds operational data. The selected workflows and a configuration of the modular inventory storage system correspond to the current state of the warehouse defined by selected portions of the operational data.

A method for controlling order-fulfillment activities in a warehouse in accordance with an embodiment of the present invention includes controlling fulfillment activities in the warehouse. The method includes managing the configuration of workstations for order fulfillment, inventory induction, or order packing operations. The configuration of a modular inventory storage system is also controlled. The method includes recording operational data corresponding to the fulfillment activities in the warehouse. The operational data is held in memory. The control of the fulfillment activities in the warehouse and the configuration of storage systems are defined by a plurality of selected workflows that are selected from a workflow library. The selection of workflows and the configuration of the modular inventory storage system correspond to the current state of the warehouse defined by selected portions of the operation data and expected demands.

In an aspect of the present invention, the order-fulfillment system includes a unit sortation system that includes a plurality of autonomous mobile robots (AMRs), each configured to move inventory items from one location to a desired next location.

In another aspect of the present invention, the modular inventory storage system includes one or more different storage techniques. A particular storage technique may either add or remove additional storage modules to the modular inventory storage system or add or remove additional storage resources to a module of the modular inventory storage system according to current or expected demands.

In a further aspect of the present invention, a workflow control module includes one or more function calls, with each function call a microservice.

In another aspect of the present invention, the reconfigurable workstations are configured to perform one of the following operations: order fulfillment, inventory induction, or order packing operations. The reconfigurable workstations will also be configured for use by humans and/or robots.

In a further aspect of the present invention, the control system is capable of determining or identifying a priority level of a newly received order. Inventory allocated for one or more previously received orders may be reallocated to the newly received order if necessary to meet the newly received order's customer service level agreement (“SLA”) if the newly received order has a priority level higher than the previously received orders.

The present invention thus provides an adaptable system and method for order-fulfillment activities within a warehouse facility that is configured to dynamically adapt to current operational conditions and/or expected demands. Through the use of modular storage systems, reconfigurable workstations, and control systems using selectable workflow control modules selected from a workflow control module library, the order-fulfillment activities may adapt to those changing conditions in real-time or near real-time. Such adaptations include dynamically increasing or decreasing inventory storage space, reconfiguring workstations to perform a selected order fulfillment activity or inventory induction/decant operation, and updating the selected workflow control modules selected from the workflow control module library. These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.

The present invention will now be described with reference to the accompanying figures, wherein numbered elements in the following written description correspond to like-numbered elements in the figures. While conventional warehouse environments (e.g., order fulfillment systems) traditionally rely on “set in stone” automated and manual hardware and processes in which various components or sub-systems are configured for particular dedicated operations and are not adjustable, the exemplary order fulfillment and control system is configured to provide adaptive operational capabilities to avoid such “set in stone” features. Embodiments of the present invention provide methods and a system for a decoupled and modular order-fulfillment facility with intelligently orchestrated and dynamic workflows for demand-driven flexibility and productivity. Exemplary embodiments are configured to dynamically change how orders are fulfilled in/near real-time based on, for example, customer demands and resource optimization via intelligent orchestration to flexibly adapt flexible physical infrastructure and dynamic reconfigurable workflows in response to changing needs. An exemplary facility includes reconfigurable subsystems, which are substantially automated and multi-functional for item storage, carton erection, receiving, picking, inducting/decanting, sorting, consolidation, and packing. These various subsystems are directed to, but not limited to, item storage, receiving, decanting/induction, picking, sorting, packing trailer yard control, and carton erection. Such dynamic reconfigurability includes flexibly adding or reducing order fulfillment capacity (e.g., reconfigurable multi-purpose workstations (e.g., picking, decanting/induction, and/or packing), adding/decreasing inventory storage to a modular storage system, human or robot workers, and flexible automation solutions) temporarily or permanently, and adapting the capabilities over time allowing for flexible modular up/down-scaling. Such reconfigurable subsystems are controlled by a control system that is operable to select operational workflows from a workflow library, select particular operational configurations for reconfigurable workstations, and to adaptively control inventory storage of a modular storage system without requiring reprogramming of the control system based upon the current operational conditions and expectations. An exemplary method for multi-channel fulfillment includes a combination of fixed automation, flexible mobile automation, and modular process/control systems. Exemplary fixed automation includes automated storage and retrieval systems (AS/RS) and unit (i.e., single item) sortation systems (e.g., cross-belt sorter, and sorting mezzanines). Exemplary mobile automation includes bin transportation (e.g., bin-to-person AMRs), sortation inventory routing AMRs, and customer designated solutions (e.g., shelf-to-person AMRs). Exemplary modular process/control systems include a warehouse controller, control system, or orchestrator, a fulfillment control and monitoring system, a warehouse management system (WMS), a warehouse execution system (WES), and a supply chain management system.

An exemplary order-fulfillment facility or host facility's warehouse management system includes order information which is provided to the control system. As described herein, the control system controls the execution of orders (e.g., the aggregation and controlled release of orders (and the timing of those orders), allocation of inventory to fulfill the orders (including a consideration of reallocation of inventory to fulfill high priority orders)) for fulfillment within the facility. An exemplary order-fulfillment system includes a plurality of order channels. Each order channel may be defined according to its particular downstream resources and/or requirements. For example, the released order may be directed to picking items that are going to a “put wall” downstream, or for the picking of items put to a grid for a larger store or retail establishment. Other order channels include single-unit e-commerce, multi-unit e-commerce, retail/store, value added services (VAS), etc.

1 1 FIGS.A andB 1 1 FIGS.A andB illustrate exemplary warehouse environments or aspects thereof in which order fulfillment activities are taking place. It should be appreciated that order fulfilment systems employing control systems in accordance with the present invention may be configured and employed in numerous ways and environments utilizing variously configured and differing material storage and handling systems. Accordingly, the below discussion of the systems ofshould be understood as non-limiting and provided for explanatory purposes.

1 FIG.A 1 FIG.A 1 FIG.A 102 104 106 108 102 102 108 102 110 With reference to, an exemplary configurable warehouse or storage facility for order fulfilment is disclosed for use with control systems in accordance with aspects of the present invention. As illustrated, the order fulfilment facility includes an inbound operations zone A, an inbound flex zone B, an order fulfillment zone C, a consolidation and packout zone D, and a shipping operations zone E. The respective “zones” are defined/outlined inwith respective dashed lines. The inbound operations zone A comprises a receiving operations areawhich is configured to deliver items to a package decant areaand an offline/manual storage area, which is part of the order fulfillment zone C. The inbound flex zone B comprises a cross-decking areaand the receiving operations area. As illustrated in, the receiving operations areais a part of both the inbound flex zone B and the inbound operations zone A. The cross-docking areareceives items from the receiving operations areaand delivers items to a shipping execution areaof the shipping operations area E.

112 106 112 106 114 116 112 106 118 114 120 116 122 118 282 200 1 FIG.A 2 FIG.B The order fulfillment zone C comprises an automated storage and retrieval (AS/RS) racking areaand the manual/offline storage area. The AS/RS racking areaand the manual/offline storageare configured to store inventory items. As described herein, the inventory items are picked by picking areas,from the AS/RS racking areaand the manual/offline storage, respectively, to fulfill orders. The order fulfillment zone C also comprises an “eaches” sortation areafor feeding items (e.g., individual items) from the picking areato a pre-pack consolidation area. As illustrated in, the picking areais configured to deliver items to a pre-pack consolidation area. In one embodiment, the eaches sortation areais also configurable to provide order line induction (e.g., multiple of the same SKU to sortation).illustrates the distribution of eaches sorted (individually sorted) itemsin the warehouse environment.

120 122 120 124 126 122 126 128 110 128 126 110 The consolidation and packout zone D comprises the pre-pack consolidation areas,(which are considered part of both the consolidation and packout zone D and the order fulfillment zone C). While the pre-pack consolidation areadelivers items, such as in totes, to an order tote transportfor delivery to a packout areawhere the items in totes are containerized, the pre-pack consolidation areadelivers items (in totes) directly to the packout area. Lastly, shipping operations zone E comprises a shipping container sorterand the shipping execution area. The shipping container sorterreceives shipping containers from the packout areaand in turn sorts them and delivers the totes/containers of items to the shipping execution area.

1 FIG.B 1 FIG.B 202 204 206 202 204 206 202 204 202 204 206 202 204 206 With reference to, an exemplary warehouse environment includes a variety of different agents,,. Each class of agents has distinct characteristics, objectives, and capabilities. The agents illustrated ininclude human pickers, robotic pickers (which usually come in the form of autonomous mobile robots (AMRs), and item carrying vehicles in the form of automated guided vehicles (AGVs) or autonomous mobile robots (AMRs)configured to carry items picked by the human pickersand/or the robotic pickers. Alternatively, the AGVs may be substituted with AMRs configured for carrying the picked items. The overall logistics of the warehouse would be distributed across the classes of agents,,. Additional agents would include fixed automation assets in the warehouse as well as fulfillment management systems (e.g., WES, WCS, and WMS). The agents,,are allocated and/or assigned to one or more order channels within the warehouse (which are managed by the order-fulfillment system).

300 300 The exemplary multi-channel order-fulfillment systemis configured to meet a variety of customer order expectations (extensive product options, next day or same day delivery, simplified processes for returns and exchanges, and competitive pricing). Adding complications to the multi-channel fulfillment system, the above customer order expectations are expected to keep changing over time. That is, the best or most optimal way to fulfill an order at one point in time, such as today, may not be the best or most efficient way to fulfill an order at another point in time, such as tomorrow (or some day in the future), or even another time within the same day. Thus, the infrastructure technologies (and associated fulfillment control systems) used within an order-fulfillment system will change as warehouse/order fulfillment system technologies continue to change. It is also expected that customers will continue to change their buying habits and expectations, thus forcing companies to “keep up” in order to remain competitive.

300 300 Accordingly, because companies need the ability to quickly adapt their operations based on customer demands and expectations, their order-fulfillment systems will need the ability to change how tasks are completed within the respective order-fulfillment systems, as well as have the ability to seamlessly incorporate different technologies into their respective operations as the need dictates. In addition, the companies (and their fulfillment systems) need to leverage their data to gain better visibility into their operational performance, anticipate customer demands, and move towards a more autonomous, self-adapting, and self-healing supply chain. To achieve this reality, exemplary multi-channel order-fulfillment systemsrequire a powerful, reconfigurable supply chain control solution that provides configurable workflows that leverage (current) best in class distribution functionality. The exemplary multi-channel order-fulfillment systemoptimizes and “orchestrates” work across any combination of humans and machines, and provides a wholistic view inside the facility, within surrounding regions, and across an entire supply chain that enables data-driven autonomous decision making.

1 2 2 FIGS.A,, andA 2 FIG.A 300 301 301 301 302 303 304 305 301 Referring to, an exemplary multi-channel order-fulfillment systemcomprises a control systemimplemented with a variety of hardware and software that make up one or more computer systems or servers, such as operating in a network, comprising hardware and software, including one or more programs, such as cooperatively interoperating programs. For example, an exemplary embodiment can include hardware, such as, one or more controllers or processors configured to read and execute software programs. Such programs (and any associated data) can be stored and/or retrieved from one or more storage devices. The storage devices can be implemented as software-based, hardware-based, and/or hardware and software-based storage devices. The hardware can also include power supplies, network devices, communications devices, and input/output devices, such devices for communicating with local and remote resources and/or other computer systems. Such control system embodiments can include one or more computer systems and are optionally communicatively coupled to one or more additional computer systems that are local or remotely accessed. Certain computer components of the exemplary embodiments can be implemented with local resources and systems, remote or “cloud” based systems, or a combination of local and remote resources and systems. The software executed by the computer systems of the exemplary embodiments can include or access one or more algorithms for guiding or controlling the execution of computer implemented processes, e.g., within exemplary warehouse order fulfilment systems. As discussed herein, such algorithms define the order and coordination of process steps carried out by the exemplary embodiments. As also discussed herein, improvements and/or refinements to the algorithms will improve the operation of the process steps executed by the exemplary embodiments according to the updated algorithms. The order-fulfillment system's control systemas described may comprise a warehouse control system (WCS). As discussed herein, the control systemcan include an order-fulfillment control and monitoring system, a warehouse management system (WMS), a warehouse execution system, and a supply chain management system. Whileillustrates components of the warehouse control system, such components can be grouped differently or implemented as separate components.

1 2 FIGS.A and 300 As illustrated in, an exemplary multi-channel order-fulfillment systemcomprises inbound and outbound functional areas controlled by associated process controls. The inbound functional area includes sub-systems (inbound operations and inbound flex) comprising material handling modules (e.g., receiving operations area, inventory slotting area, and storage strategy area; and return operations area; and cross docking area, respectively). The outbound functional area includes sub-systems, such as an order fulfillment area, consolidation and packout areas, and a shipping operations area. These sub-systems include material handling modules (e.g., a decant area (robotic and manual decant), an automated storage and retrieval systems (“AS/RS”) area (e.g., a Dematic Multishuttle® system (“DMS”), Autostore® warehousing systems, or the like)), picking functionality (e.g., robotic and manual picking), and “eaches” sortation (AMR based); an order tote/shipper sorter (AMR based), a pre-pack consolidation area, a carton erector area, and a packout area (automated and manual packout; and shipper container sortation (AMR based) and shipping execution, respectively.

2 FIG.B 2 FIG.B 1 FIG.A 2 FIG.B 2 FIG.B 2 FIG.B 200 214 214 294 200 214 216 222 216 262 260 222 220 262 260 224 262 260 228 220 260 218 218 270 230 254 224 262 260 256 254 228 260 262 230 232 218 260 230 illustrates an alternative arrangement of components for a multi-channel order-fulfillment system operating within an exemplary warehouse environment.illustrates an exemplary warehouse software subsystem in communication with a fulfillment control and monitoring system (e.g., control tower subsystem), an inbound operations subsystem, an order fulfillment subsystem, and a shipping subsystem (see also). As illustrated in, the warehouse software subsystem includes microservices associated to mechatronics modules implied with each module box. As discussed herein, the warehouse software subsystem receives process optimizations from the control tower subsystemthat are based upon datacollected from the various subsystems of the warehouse environment. The control tower subsystemmay be a cloud/on-premises enterprise network configuration, or other forms of off-premises or hybrid cloud network configuration. The inbound operations subsystem includes a receiving/dock door check-in, which is serviced by trailer unload(which includes case fluid unloading and pallet unloading). Note that the receiving/dock door check-inprovides for dock door check-in of the trucks at respective dock doors for unloading. The unloaded palletsand cases(from trailer unload) are delivered to receiving, which delivers pallets/cases,to a cross dock(which includes static conveyor and manual lift trucks) and palletsand casesto a “teach in”. Note that receivingalso delivers casesto a case reserve, which provides for a case storage area in the inbound operations subsystem. As described herein, case reservealso provides full casesto a manual decantof the order fulfillment subsystem, as well as to a destination staging areaof the shipping subsystem. As illustrated in, the cross dockbypasses the order fulfillment subsystem and delivers pallets(via manual lift trucks) and cases(via a static conveyor) directly to a truck loading service(which includes case fluid load and pallet load) and the destination staging areawithin the shipping subsystem (respectively).also illustrates the “teach in”delivering casesand palletsto the manual decantand the manual pallet reserve storage (with manual lift trucks), respectively, within the order fulfillment subsystem. The case reservealso delivers casesto the manual decant.

2 FIG.B 230 266 266 266 268 264 220 As illustrated in, manual decantalso receives mixed SKU totesfrom a returns routing management, which receives mixed SKU totesfrom a returns processing and a returns storage. The returns storage in the inbound operations subsystem receives mixed SKU totesfrom the returns processing. The returns storage provides empty totesto the returns processing and mixed SKU inventoryto the receiving.

260 218 228 262 232 230 272 242 272 238 242 230 268 266 260 262 242 272 244 244 268 242 244 282 246 282 248 232 262 230 234 252 234 276 236 280 236 232 240 232 274 240 236 282 240 232 236 240 240 284 248 240 268 248 248 282 240 Receiving casesfrom the case reserveand the “teach in”, and palletsfrom the manual pallet reserve storage, the manual decantfills totes(that it receives from storage) as either pure or mixed SKU totesand delivers them to a decant to storage(which includes a static conveyor) for eventual delivery to storage(which include a variety of storage means, e.g., DMS). The manual decantreceives empty totes, mixed SKU totes, and casesand pallets. The storagealso sends and receives pure and mixed SKUtotes to/from induct stations(which include manual induction and robotic induction). The induct stationsalso pass empty totesback to the storage. The induct stationspass inventory items (e.g., eaches or individual item sortation) to unit sortation(e.g., Tompkins T-Sort and other sortation systems), which passes the eaches sortation resultsto a pre-pack consolidation. The manual pallet reserve storagesends palletsto the manual decant, to an “each pick/forward” pick face storage (which includes trolley/cart and tote/containers), and to shipping sortation(of the shipping subsystem). The each pick/forward pick face storagedelivers totes(non-sorts via cart) to a putwall (non-sortable)and receives empty carts/containersin return. Both the putwall (non-sortable)and the manual pallet reserve storagedeliver inventory to packing. The manual pallet reserve storagedelivers non-conveyable (non-sort) inventoryto packing, while the putwall (non-sortable)delivers eaches sorted (individually sorted) itemsto packing. The manual pallet reserve storageand the putwall (non-sortable)deliver their inventory to a manual pack of the packing. An auto pack of packingreceives order totesfrom the pre-pack consolidation, while auto pack (of packing) delivers empty totesto the pre-pack consolidation. Note that the pre-pack consolidationalso delivers eaches-sorted itemsto the manual pack of packing.

250 252 254 256 250 286 240 288 248 250 290 290 254 254 262 232 270 218 292 254 256 256 260 262 256 260 262 256 262 260 258 258 258 256 2 FIG.B The shipping subsystem includes a shipper transport (static conveyor), a shipping sortation (crossbelt sorter), a destination staging (pallet build and Gaylord deposit), and truck loading (case fluid load and pallet load). As illustrated in, the shipper transportreceives auto packed or manual-packed ordersfrom packingand autobagged ordersfrom the autobagger (at a putwall) of the pre-pack consolidation. The shipper transportdelivers packed ordersto the shipping sortation, which delivers the packed ordersto destination staging. The destination stagingalso receives palletsfrom the manual pallet reserve storageand full casesfrom the case reserve. The consolidated packed ordersare delivered by the destination stagingto truck loading. Truck loadingalso receives casesand palletsfrom the cross dock (from static convey and manual lift trucks, respectively). Case fluid load and pallet load of the truck loadingreceives the casesand pallets, respectively. The truck loadingdelivers the palletsand casesto shipping (dock door check-in)for truck loading at the respective dock doors. Note that shipping dockincludes dock door check-in for those trucks received at shipping dockfor load (via the truck loading).

301 301 300 352 301 301 352 While many existing or conventional warehouse solutions could be categorized as “flexible, scalable, and modular,” such conventional warehouse solutions do not provide day-to-day operation at desired efficiency, while also allowing modularity of the fulfillment system in terms of being able to add new material handling modules/technologies to the fulfillment system either temporarily or seasonally to meet increasing/changing demands, and to downscale as needed to save costs when demands are not as high. The exemplary multi-channel fulfillment system is also configured to dynamically meet changing operational needs by adding or removing physical fulfillment infrastructure modules and modifying operational workflows without needing to involve technical resources and rewriting process control, and thereby maximizing productivity, throughput, and capacity at low cost. That is, additional fulfillment resources may be either added when the need is anticipated and then removed afterwards, or an existing surplus fulfillment resource that is temporarily added when needed and then deactivated afterwards. The physical placement and removal of fulfillment resources could be for anticipated large additional fulfillment needs (e.g., during expected holiday demand bursts), while the activation/deactivation of the surplus resources could be for short-term increases and decreases that occur more frequently (and less predictably). As used herein, “module” is used to describe a discrete component of physical infrastructure or of a process or function (e.g., the control system). That is, as discussed herein, while the control systemincludes an architecture that is broken into interchangeable and reconfigurable components, the physical infrastructure of the order-fulfillment systemis also divided up into discrete components or modules. For example, multiple configurable workstationscan be reconfigured for particular order-fulfillment activities (and with their portion of the control systemcorresponding to the particular microservices that control their operations added or updated to the control system). Thus, the multi-purpose workstationsare able to adapt processes as required.

300 The multi-channel fulfillment systemin accordance with aspects of the present invention enables the operational parameters of a given sub-system, such as a pick station, a put station, a decant station, or the like, to be altered so as to operate in another manner, such as reconfiguring operation of a pick station to a put station or the like, including by changing from human operation to robotic operation. Furthermore, such sub-systems can include, for example, reconfigurable workstations that may be selectively configured (and selectively reconfigured as needed) for any of a plurality of configurations, such as, order fulfillment operations, inventory induction, order packing, and the like. Such sub-systems can also include storage modules of a modular inventory storage system configured to store inventory items. Such storage modules can comprise one or more different storage techniques. The configuration of the modular inventory storage system can also include adding and/or removing additional storage modules in the modular storage system according to current and/or expected demands (e.g., daily versus weekly depends). Moreover, the control system is configured to monitor the order fulfillment requirements of the warehouse and manage the reconfiguration warehouse sub-systems to optimize the order fulfillment operations, with the control system correspondingly altering both the control of the particular sub-system through the selection of workflows from a library of workflows, and the selective configuration of reconfigurable workstations, and the configuration of storage modules of the modular storage system. Such selection of workflows, configurations of reconfigurable workstations, and configurations of storage modules of the modular storage system are executed by the warehouse control system without requiring additional programming or reprogramming.

300 The exemplary multi-channel fulfillment systemprovides warehousing logistics operations including inbound operations, storage and inventory, order fulfillment operations and outbound operations as well as supply chain features, such as global inventory management and distributed order manage. The exemplary multi-channel fulfillment system and methods allow warehouse capacity and capabilities to scale and change flexibly over time to meet fluctuating and seasonal demands. It is characterized by quickly and easily being adaptable without having to customize or redesign, and therefore cost efficiently adapt as the operations. The exemplary multi-channel fulfillment system and methods also use real-time or near real-time data to intelligently orchestrate inventory and order flows in a warehouse/fulfilment center by controlling automated parts of the warehouse/fulfilment center and advising warehouse managers and operators (decision support) on current performance and how to configure workflows to maximize productivity, throughput, and capacity.

2 4 FIGS.- 2 FIG.A 300 300 300 318 404 406 408 314 352 354 300 301 302 303 304 305 301 306 294 304 306 303 305 301 303 305 With references to, exemplary embodiments of a multi-channel order-fulfillment systemavoid conventional “set in stone” features by avoiding a strictly defined facility layout and dynamic control process. Instead, an exemplary order-fulfillment systemcomprises a plurality of reconfigurable solutions for controlling the order fulfillment, which includes reconfigurable infrastructure sub-systems and associated control systems with modular architecture. The multi-channel order-fulfillment system is able to scale up/down over a day/week/month time horizon in a dynamically adaptable fashion in (or near) real-time. An exemplary multi-channel fulfillment systemcomprises a modular physical architecture with a centralized sortation systemconnecting one or more generic storage types,,(regardless of storage technology and/or technique) and associated pick faceswith manual and robotic multi-purpose workstations(each configured to adapt their order-fulfillment processes and/or operations based on workflow changes) and a transportation system that uses AMRsfor transportation and buffering. As illustrated in, an exemplary modular order fulfillment systemincludes a dynamically reconfigurable warehouse controller, control system, or orchestrator, a fulfillment control and monitoring system, a warehouse management system (WMS), a warehouse execution system (WES), and a supply chain management system. The warehouse controller (control system)is communicatively coupled to memorythat retains operational dataand a microservice library(i.e., API library). Where memorymay comprise one or more hardware and/or software components, such as memory modules. In one embodiment the WMSand the supply chain management systemare implemented as separate systems within the warehouse control system, alternatively, the WMScan be a sub-component of the supply chain management system.

318 318 318 318 3 4 FIGS.and The exemplary centralized sortation system(see) is configured to receive inbound items from other subsystems, such as inventory storage locations, a receiving subsystem, a decant/induction subsystem, or the like. The sortation systemreceives items and moves them to the correct “next” location. An exemplary sorter may be as described in commonly assigned U.S. Pat. No. 7,086,519, issued Aug. 8, 2006, which is hereby incorporated herein by reference in its entirety. As discussed herein, an exemplary sortermay be configured as an extensive system of conveyors, etc., or may use AMRs. In one embodiment, the exemplary sortmay include cross-belt sorters, sorting mezzanines, and Bombay-style sorters.

2 FIG.A 8 8 FIGS.A andB 301 302 303 304 305 301 301 301 301 As illustrated in, the multi-channel order-fulfillment system's exemplary control systemcombines an order-fulfillment control and monitoring systemand traditional WMS, WES, and WCSfunctionality into a single solution that allows for modular custom deployments that are tailored specifically to meet each customer's requirements, all while leveraging a standard and evolving toolkit of warehouse and supply chain functionality. The exemplary control systemutilizes standard warehouse and yard functions that execute all warehouse activities from receiving, storage, picking, sorting, packing, shipping, and inventory control. These warehouse and yard functions all exist as “microservices,” which as described herein, can be configured into customer-specific configurable workflows that are designed to meet the need of each customer (see). As used herein, a microservice is a “building block” or component of a software architecture that divides a program or application into components based upon the services those individual components (microservices) provide or perform. That is, a microservice is a component of an application that provides one or more services for the application. Each individual service within an exemplary microservice would be developed and maintained as a separate and discrete piece of software. Such arrangement allows a microservice (and its services) to be considered a “plug-n-play” component of a larger application or program (e.g., the control system). When there are multiple microservices (each with their own discrete services), these microservices can be interconnected together and communicate with each other via application programming interfaces (“APIs”). The advantage of a microservice architecture for the control systemis that additional (or updated) microservices can be easily created and added to the control system, without the need to rewrite code, thus cutting down on the amount of time and effort required to implement and adapt these workflows. Just as traditional WMS allowed for multiple ways to complete warehouse tasks (e.g., RF, voice, lights, paper), flexible fulfillment allows for the use of various fixed and flexible automation technologies and software solutions to be incorporated into a customer's configurable workflows.

10 FIG. 10 FIG. 301 In one embodiment, an exemplary dynamic control process includes a process solution that controls the multi-channel order-fulfillment system. The dynamic control process is built with a modular architecture that includes a set of selected microservices from a library of microservices. The modular architecture of selectable microservices provides for maximized productivity, throughput, and capacity in the multi-channel fulfillment system. The dynamic control process comprises an intelligent orchestration or system control that uses an end-to-end inventory fulfillment logic to orchestrate (or control) the inventory and resources to efficiently fulfill customer orders. As described herein, the processes for dynamic and configurable workflows are built using a “drag-and-drop” or user-selection configuration via a user-friendly software interface which enables real-time configurable dashboards to inform warehouse managers and operators on warehouse conditions and exceptions, and to advise on root causes and recommended actions including recommended workflow configuration changes (see). The exemplary processes for flexible modular infrastructure component up/down-scaling is also based on “plug-and-play” infrastructure material handling components (e.g., reconfigurable workstations, a storage system that includes a plurality of inventory storage means without regard for their particular storage techniques, transportation means, and automation) available through a catalog of pre-built infrastructure integrations, and enabled through standardized microservices, such as found in an exemplary automation marketplace comprising a library of APIs (see). For example, one or more pick stations may be selectively added or removed, in which the pick station may be readily connected structurally as well as electronically in terms of controls, with the control systemincluding a software interface (comprising a selected set of microservices necessary to perform the needed services/functions of the pick station) configured to readily enable such pick stations to be added or removed without the necessity of programming.

As described herein, the exemplary fulfillment control and monitoring system provides monitoring and machine learning and artificial intelligence functionality for predictive analytics of the fulfillment process within the multi-channel order-fulfillment system, e.g., changes in operational performance, changes in order or item demand, and potential automation system maintenance issues. Thus, a customer's entire supply chain may be managed by managing global inventory across a customer's entire distribution network, including managing inventory positioning based on predicted customer demand as well as managing global customer orders and distributing orders to appropriate fulfillment centers to ensure customer commitments are met. For the fulfillment system to autonomously update configuration changes, adjust business rules, and adjust the allocation of resources within a fulfillment center or across the supply chain based on changing business conditions.

300 301 301 An exemplary multi-channel fulfillment systemwith flexible architecture decouples the fulfillment workflows (executed by the warehouse control system) from technology and is capable of dynamically changing how orders are fulfilled in or near real-time based on customer demands and resource utilization (via intelligent orchestration at the warehouse control system) flexibly adapting capabilities over time (flexible module up/down-scaling).

2 3 4 FIGS.A,, and 300 301 300 301 With reference to, an exemplary multi-channel fulfillment systemincludes a flexible fulfilment physical architecture, a control systemconfigured to control execution within the multi-channel fulfillment centerand across the supply chain, processes for intelligent orchestration (at the warehouse control system), processes for dynamic and configurable workflows, and processes for flexible modular up/down-scaling via an automation marketplace of modular subsystems (physical inventory handling and storage subsystems and logical subsystems). An exemplary automation marketplace includes any one or more of the following: subsystems and configurations for materials handling, sorting, inventory storage, transportation, and reconfigurable workstations.

2 3 4 FIGS.A,, and 1 312 314 2 318 3 352 4 354 312 314 352 As illustrated in, an exemplary flexible physical architecture for order fulfillment in a warehouse environment comprises:) a storage system(with one or more generic storage types) and associated pick faces,) a unit sortation system,) multi-purpose workstationsthat are able to adapt to different processes (e.g., decant/induction operations, order fulfillment operations, and packing operations; as well as configurations for human or robotic workers), and) AMRsfor transportation and buffering between the storage types/pick facesand the multi-purpose workstations.

300 352 352 352 352 352 300 352 352 352 301 312 a c 5 FIG. The multi-channel order-fulfillment systemmay be configured in such a manner that a varying quantity of reconfigurable workstationsare configured and “activated” as necessary to meet throughput requirements in the warehouse facility. For example, a plurality of reconfigurable workstationsmay be configured for any type of operation or service, e.g., a variable quantity of available workstations-may be configured for induction/decant operations, while another variable quantity of the available reconfigurable workstationsare configured for packing operations. It will be appreciated that due to the reconfigurable nature of the workstationsbeing capable of operating as any available configuration, various portions of the order-fulfillment system(e.g., containing reconfigurable workstations) can be operated differently at different times of the day, as needed. The workstationscan be reconfigured substantially instantaneously as soon as all prior functions have completed. To increase flexibility, the reconfigurable workstationsare configured for human activities and/or robotic activities. The multi-channel fulfillment facility's control systemsynchronizes various order-fulfillment functions and processes, including the sequencing of various sized shipping containers or pick totes (when in a picking or packing function) or various sized vendor cases or item containers (when in a decanting/induction function) with inventory/donor containers from, for example, an automated storage and retrieval system of the storage systemat a goods-to-person (GTP) or goods-to-robot (GTR) workstation to maximize productivity of the operations and throughput of the facility (see).

300 404 406 408 312 312 312 402 402 404 406 408 404 406 408 312 418 418 312 312 312 314 314 312 300 312 314 312 202 204 312 314 312 354 a b a a a; b b b a b The multi-channel order-fulfillment systemincludes a plurality of different inventory storage technologies and operations as segments (e.g., storage subsystem A, storage subsystem B, and storage subsystem C, where each subsystem is a different inventory storage technology) within an overall storage system. A common or modular architecture allows the storage systemwith different units of measure (between the different storage subsystems) to be interchangeable and reconfigurable. In one embodiment, an exemplary storage systemis configured as a modular storage system comprising, for example, a pair of storage systems,, each including a set of storage subsystems,, andand,, and, respectively. The storage systemincludes automated and manual storage options that can be added or removed, whether individual storage units or additional shelves within a storage unit (e.g., non-sortable inventory storage,). Either adding/removing storage components to/from the storage systemor adding/removing storage modules to the storage system. For example, the storage types (of the storage system) and pick facescan be automated storage and retrieval systems (AS/RS) with dense storage, high velocity storage types (AMR S2P (“shelf to person”)/B2P (“bin to person”)), or static shelf/manual pick (considered “low velocity,” reserve, and “non-totable”). The storage pick stationscan be goods-to-person or goods-to-robot and can handle both batch picking and induction to the sortation system. In one embodiment, the storage systemincludes an AS/RS storage system where either portions of its storage capacity can be “deactivated” or shut down when the storage capacity exceeds the needed space. Alternatively, the AS/RS storage system could include storage modules that may be coupled as needed to the whole AS/RS storage system as need (and uncoupled (and optionally removed) when unneeded). Note that the unused portions of the AS/RS storage system or the unused storage modules will be empty, set to minimal or no power requirement and minimal to no maintenance requires to reduce operational overhead and costs. Note that the multi-channel order-fulfillment facilityincludes storage systemswith pick facesalong portions of the storage systemthat is immediately accessible to an order picker (e.g., human pickerand/or robot picker). Thus, as items are moved from a pick face, the storage systemwill need to replenish the storage locations at the pick facefrom other storage locations within the storage system. This transferal of items may be accomplished with AMRsor other automated means. Note that additional inventory storage modules can be either added when the need is anticipated and then removed afterwards, or activated when needed and deactivated afterwards. The physical placement and removal of storage modules could be for anticipated large additional inventory storage needs (e.g., during expected holiday shopping bursts), while the activation/deactivation of storage modules could be for short term increases and decreases in demand.

318 318 318 2 2 3 4 FIGS.A,B,, and 3 4 FIGS.and The unit sortation system, illustrated in, allows any unit picked from any pick medium to be transported for consolidation and/or packing to any pack-station. The unit sortation systemcan be implemented as a centralized system, a decentralized system, or a distributed system. The unit sortation systemcan be automated using an AMR solution and can sort to discrete multi-line order or multiple single-line order consolidation points. Circular, cross-belt, linear sorters, or Bombay-type sorters are commonly used for unit sortation. While an exemplary AMR-based unit sortation system is one exemplary embodiment, alternative embodiments can include crossbelt or Bombay-style sortations (complementing or replacing AMRs).illustrate a general overview of sortation with, for example, AS/RS storage. In one such arrangement an optimal layout may utilize a Dematic Multishuttle System (“DMS”) and the unique capabilities of DMS to “pre-sort” donor totes to DMS lifts. Such a system may be configured in accordance with U.S. Pat. No. 9,555,967, which is hereby incorporated herein by reference in its entirety.

5 FIG. 5 FIG. 502 504 502 504 318 Referring to, an exemplary AS/RS storage moduleis associated with a material conveyancefor moving donor totes in and out of the AS/RS storage module. Note that while the conveyorsillustrated inutilize conveyors and other similar means for inventory movement, AMR sort modules (e.g., the unit sortation (AMR) system) could also be used.

300 354 354 300 352 300 3 FIG. Exemplary AMRs for transportation and buffering are used through the flexible, modular order-fulfillment system(see AMRsof). The AMRsare used for automated and flexible transportation throughout the order-fulfillment system. This allows for more even workflow distribution between pack stations (and the reconfigurable workstations) and helps to maximize throughput. The AMRs allow physical workflows to rapidly change without infrastructure changes. This allows the exemplary modular order-fulfillment systemto quickly scale up or down (in physical infrastructure). Such arrangements lead to greater sustainability through less energy usage versus traditional conveyance means or sortation.

416 4 FIG. An exemplary pack buffer(see) de-couples packing stations and enables post-consolidation order sequencing. While induction stations are configured as workstations where product is placed onto sortation, pack stations are configured very simply (e.g., a simple workbench of sorts). The pack destination is not limited by conveyance and a predetermined path, providing the opportunity to redirect “ready-to-pack” orders to balance the workflow. Additionally, higher priority orders can bypass lower priority orders, prioritizing packing capacity and increasing on-time shipping probability compared to more fixed conveyor-based solutions.

6 6 FIGS.A andB 352 352 With reference to, an exemplary process for a goods-to-person (GTP)/induction workstationis illustrated. Exemplary multi-purpose workstationsare configured to adapt processes based on workflow changes (e.g., induction, picking, packing, etc.). Manual and robotic/automated packing stations provide for interchangeability in fixed automation/mobile/human. As described herein, the exemplary packing stations allow for operation by both human and robot. Automated packing modules allow operations to progress to full automation over time without significant infrastructure changes. In one embodiment, exemplary packing modules are not physically connected to sortation or consolidation, enabling the adding of additional modules to increase order-processing capacity. Additionally, because any unit can arrive at any pack station, from any pick location, higher batch factors can be achieved in picking, increasing operational efficiency.

352 602 604 352 606 318 608 610 612 614 612 614 626 612 616 618 301 318 620 622 620 624 628 626 630 626 630 630 628 628 632 632 634 636 638 640 318 638 642 6 FIG.B An operational process for an exemplary goods-to-person (GTP)/induction workstationstarts in step. In step, inventory arrives at the induction/(GTP) station. In step, a determination is made as to whether an AMR configured for sorting (a sorting AMR) is ready for induction (part of the unit sortation system). If the sorting AMR is not ready for induction, then the process proceeds with step, where the user (or robot arm) awaits until the AMR is available. When the sorting AMR is ready for induction, the process proceeds with step, where the user (or robot arm) picks inventory item(s) from a retrieved bin. Optionally, the process includes step, where the inventory item is scanned, and a pick verification control is executed. The process proceeds to step, where the user or robotic arm places inventory item(s) onto the sorting AMR. If stephas been performed, then after step, the process proceeds to step. If stephas not been performed, then the inventory is scanned in step. In step, an interface is sent from a fulfillment activities controller (e.g., warehouse control system) to a sorting controls layer (of the unit sortation system). In step, pick verification occurs. In step, a determination is made as to whether the pick is complete. If the pick is not complete, the process flow returns to stepand the pick verification reoccurs. If the pick is complete, the process proceeds to step, where a determination is made as to whether there is a re-direct opportunity available. If there is not, the process proceeds to step. If there is an opportunity for re-direction, then the process proceeds to step, where a destination order tote allocation occurs. In step, a determination is made as to whether the bin allocation is finished. If the bin allocation is not finished, the process returns to step, where the destination order tote allocation continues and then returns to stepfor further processing. If the bin allocation is finished in step, the process proceeds on to step, where an AMR executes a route to a destination order tote. After step, the process proceeds to stepon. In step, the AMR arrives at the destination order tote. In step, the AMR deposits the inventory item(s) into the destination order tote. In step, the database is updated for inventory location and order status. In step, a determination is made as to whether the order bin is complete. If the order bin is complete, then the process continues to step, where the interface is sent from the sorting controls layer (of the unit sortation system) for bin pickup. If the order bin is not complete (in step), then the process ends in step.

7 FIG. 702 704 706 708 708 710 712 710 712 708 714 300 716 718 With reference to, the steps to an exemplary pick verification process are illustrated. In step, the pick verification process begins. In step, an exemplary pick verification occurs. In step, an inventory barcode is validated against a database. In step, a determination is made as to whether the scan was successful. If the scan was unsuccessful, the process proceeds to stepand a scan error with reason (for the error) is displayed to the user at the induction station. In step, the AMR is stationary until the scan is resolved. In step, a determination is made as to whether the issue is resolved. If the issue has not been resolved, the process returns to stepand the AMR remains stationary until the scan is resolved. In step, once the issue has been resolved, the process continues back to step, and the process again determines whether the scan was successful. If the scan was successful, then the process proceeds to step, where the pick is completed by the fulfillment system. In stepthe database is updated for order status and in step, the process ends.

9 FIG. 902 904 906 908 910 908 912 910 910 912 914 Referring to, an exemplary method for re-allocating already picked inventory (“pick stealing”) includes the following steps. In step, a new order is released. In step, the priority of the newly released order is compared to any previously released orders. In step, a determination is made as to whether there are inventory/items in pickable locations for the newly released order. If the inventory/items for the newly released order are in pickable locations, then the method proceeds to step. If there are inventory/items unavailable (i.e., not in pickable locations for the newly released order), then the method continues to step. In step, a determination is made as to whether the allocated inventory/items can be picked and meet the customer's service level agreement (“SLA”) for the newly released order. If the allocated inventory/items can be picked and meet the customer's SLA for the newly released order, then the method continues to stepand ends. If one or more of the allocated inventory/items cannot be picked and meet the customer's SLA for the newly released order, then the method proceeds to step. In step, a determination is made as to whether reallocating inventory/items from any previous orders with lower priorities would meet the customer's SLA for the newly released order. If reallocating inventory/items from the previous orders with lower priorities would not meet the customer's SLA for the newly released order, then the method ends at step. If reallocating inventory/items from the previous orders with lower priorities will meet the customer's SLA for the newly released order, then the method proceeds to step.

914 916 912 In step, the one or more inventory/items allocated to the previous orders with lower priorities are reallocated to the newly released order. In one embodiment, the inventory/items are only reallocated if there are additional inventory/items available to fulfill the lower priority order. In step, additional inventory/items are allocated to replace the one or more reallocated inventory/items to meet the customer SLA of the previous order(s) with lower priorities. The method ends at step.

301 300 301 300 300 301 301 301 301 An exemplary controls systemfor a multi-channel order-fulfillment systemcomprises an end-to-end inventory-fulfilment logic based on intelligent orchestration of inventory and resources to fulfil customer orders (implemented in software). The exemplary fulfillment controls logic may be configured as a “facility orchestrator” (i.e., the warehouse control system) responsible for managing the overall flow of product and task execution throughout the order-fulfillment system. The orchestrator's main function is to ensure a consistent flow of work throughout the order-fulfillment system, avoiding bottlenecks (too much inventory for the available handling/processing resources) and starvations (too little inventory such that handling/processing resources may be idle). The orchestratordecides what work needs to be completed, when it needs to be performed, and who (human) or what (machine) should perform the work. A warehouse (task) orchestratoris responsible for prioritizing, optimizing, and orchestrating work amongst human workers and automation systems, ensuring a consistent flow of work throughout the warehouse and that the right work is getting completed at the right time in order to meet customer commitments. The orchestratorautomatically adjusts the flow of task execution based on different factors including order commitment times, inventory constraints, labor constraints and performance, and equipment performance. The orchestratorcontinually evaluates what tasks need to be executed at what time and by who (human) or what (machine) in order to avoid bottlenecks and starvations and ensure customer commitment times are being met. The system maintains control of all fulfillable inventory from receiving through shipping. The system has the ability to route inventory for replenishment and fulfillment in real-time.

301 301 301 301 Functions performed by the orchestratorinclude resource management and order management. When performing resource management, the orchestratormonitors performance and utilization of resources (operators, mobile equipment, and robots), and redirects mobile resources as needed to avoid task bottlenecks or starvations. The order management includes sequencing order release at the proper time to meet customer service level agreements (“SLAs”) based on factors, such as, order fulfillment times, inventory constraints, and labor/machine capacity constraints. The orchestratormay partition orders into different order-fulfillment subsystems as needed based on where the inventory is located and performance factors. The orchestratorthen ensures proper consolidation of those partial orders before shipping.

301 404 406 408 318 301 301 When performing order management, the orchestratoris also able to perform intelligent release sequencing (units fulfilled from different storage subsystems (e.g., subsystems,, and) arrive simultaneously at consolidation point to avoid extended dwelling times. Individual units are released based on distance and pick rates, etc. Unit destinations are determined first at unit release and can be reallocated at induction to sortation (the sortation system) for multi-line orders. Single line orders may be re-allocated as far downstream as the pack station. The orchestratoralso performs intelligent flow adjustments, such as configurable order release and dynamic re-routing post-pick. Such flow adjustments are intended for waveless operation with multiple cut-off times and the fulfillment system can re-assign order unit destinations between picking and packing processes. For example, if 5:00 pm (1700 hours) is the cut off for priority orders, and it's now 9:00 pm (2100 hours) at night, the orchestratorhas the flexibility to immediately release all orders for 1700 anyway as they populate to allow for more priority orders to be serviced.

301 The orchestratorincludes a consolidation process capable of consolidating items into discrete orders (i.e., discrete order chute), batch orders (i.e., multi-order chutes), single item orders (i.e., multiple single line orders in one chute), polybag, and single item orders. Each point of consolidation (i.e., chute) can be configurable to any of the consolidated states and can be changed over the course of an operational period.

301 300 9 FIG. The orchestratoralso includes pick stealing (re-allocation) functionality (see). As higher priority orders are released, the order-fulfillment systemmay be able to “steal” products/items that have been picked for another order and re-allocate them for the highest priority order. This may occur if stealing the pick is required to meet the customer's SLA of the higher priority order or if inventory does not exist in the pickable location for the higher priority order. After the pick steal occurs the system allocates additional inventory to satisfy the lower priority order. This behavior should be configurable by the customer. The customer should be able to configure whether pick stealing is allowed, up to what point in the fulfillment process an order is allowed to be stolen from, and whether pick stealing is allowed if no additional inventory is available to fulfill the lower priority order.

301 301 300 301 301 The orchestratormanages inventory movement. The orchestratormanages the flow of inventory across the order-fulfillment systemand manages movement of inventory to different areas of the warehouse/fulfillment facility as needed. For example, the orchestratordetermines and initiates replenishments into order fulfillment subsystems as needed to ensure proper inventory balancing. Such inventory management is based on predicting customer behavior and handling SKU proliferation. It uses historic as well as current information to direct inventory put away and replenishment. Such inventory movement also includes transportation management where the orchestratorissues instructions to fixed and flexible automation systems for the movement of goods.

301 302 Lastly, the warehouse task/control orchestratorleverages control & monitoring functionality (via the order-fulfillment control & monitoring system) to monitor operations from the “four walls” of warehouse to the entire enterprise, providing insights into operation performance, alerting to process exceptions, and identifying performance degradation due to changes in labor, equipment, order profile, etc. Advanced data integration and guided workflow resolution capabilities allow the system to identify root causes of issues and provide recommendations of how to resolve issues and exceptions. The system is able to be configured to adapt system configurations autonomously or allow a human to make configuration changes. Additionally, the control/monitoring system's AI/ML capabilities (with respect to control system visibility/monitoring) are used to provide predictive analytics to forecast future changes to the customer distribution network and environment (e.g., higher demand for specific SKU's due to weather, supply chain issues, transportation delays, etc.).

300 301 301 300 301 301 Controlling order fulfillment within an exemplary multi-channel order-fulfillment systemand across its associated supply chain includes a control system(software solutions to control the execution within flexible fulfilment centers and across the supply chain) with a modular architecture that is built upon a foundation of microservices. Using microservices, the control systemis configured to control the order-fulfillment systemand to guide human workers in the warehouse facility. The exemplary control systemuses real-time or near real-time data to intelligently orchestrate inventory and order flows in the warehouse/fulfillment facility by controlling automated parts of the warehouse/fulfillment facility and advising warehouse managers and operators (decision support) on current performance and how to configure workflows to maximize productivity, throughput, and capacity. The control systemallows for opportunistically fulfilling order demand from inventory being received into the facility. Such cross dock-like functionality allows for the most efficient order fulfillment, completely bypassing storage.

300 The exemplary modular order-fulfillment systemallows for non-linear flows and decision-making, i.e., each location where an inventory unit is scanned or identified, it should opportunistically choose the next best location (sending the unit to either storage or fulfillment). A continuously updating optimization calculation using real-time data to optimize flow throughout the solution. This flexibility enables for more efficient picking upstream, combining singles and multi-pick missions; more flexible workflow to packing stations to mitigate capacity loss due to starvation; eliminate singles packing dependency and allow the operation to adapt to drastic changes in order profile (i.e., singles percentage of backlog) without moving labor.

Microservices consist of groupings of one or more code functions or services that can run as standalone services and can be easily coupled together with other microservices to build specific solutions (via APIs coupling the microservices together). Microservices contain code that execute specific functions and/or services (e.g., picking, receiving, etc.), control user interface screens, handle integrations to other systems and solutions, and process background functions (e.g., message processing, alerting, etc.).

352 352 352 Multiple instances of a microservice can be created and run at the same time to ensure proper system performance. For example, a single instance of a microservice may be used to process activity at goods-to-person (GTP) workstations. During peak hours, additional GTP workstationsmay come online causing an increase in the amount of processing that needs to occur. In response to the additional GTP workstations, the system may create additional instances of the GTP workstation microservice. When volumes drop, the additional microservices are removed. Additionally, when no GTP processing is taking place all instances of the GTP workstation microservice may be removed to ensure the system is running as lean as possible to maximize system performance. It is also important that when multiple instances of a microservice are created that task sequencing is considered. For example, having multiple instances of a microservice that is used to process messages from a conveyor may cause messages to be processed out of order.

301 301 Separation of functionality into appropriate subsystems/control modules to avoid a monolithic approach. Improved patching and upgradability by decoupling functionality and use of defined APIs between subsystems/modules to allow for independent deployment without impacting overall system functionality. Support for improved testing of functionality. Increased speed of development. Microservices help on elasticity and resilience of the system, by growing the number of instances when demand increases and reducing them when no longer needed. Developing a controls architecture using microservices allows a complex control system (i.e., the warehouse control system) to be broken down into smaller, simpler, and more manageable parts. Building the control systemthis way allows for the following benefits:

301 300 301 302 300 300 301 The exemplary control systemfor a multi-channel order-fulfillment systemcomprises a frontend interface for workflow configurations. The control systemis fed and advised by real-time and historic data (from the order-fulfillment control & monitoring system) for constant optimization. The interface is configured to inform warehouse managers and operators on conditions and to advise on action, with the ability to flexibly reconfigure warehouse workflows. Embodiments of the multi-channel order-fulfillment systemallows for fully configurable system workflows. For example, particular order-fulfillment systemsare able to tailor all system workflows by connecting different tasks to match the operational requirements of the warehouse facility. The exemplary control systemprovides default configurations for different workflows and workflow activities.

301 300 300 The control systemuses workflows that are used to define how human operators and machines complete warehouse tasks and are also used to determine how products/inventory items should flow through the warehouse/fulfillment facility. Configuration of workflows may be done using a “no code/low-code” workflow editor (see herein). This approach to workflow configuration allows a particular multi-channel order-fulfillment systemto have custom workflows that meet their needs but are built with standard functionality. This approach also cuts down on the time, effort, and cost required to implement and adapt the multi-channel order-fulfillment systemsince the configuration can be done without the need to write code.

300 301 In addition to the ability to configure the different workflows, configurations exist within the tasks that make up the workflows that allow individual customers to tailor exactly how the tasks behave (within their warehouse/fulfillment centers). These configurations are able to be performed without the need to write code. Examples of task configurations include, for example, rules for item storage, rules for inventory selection at order allocation, what information a user needs to capture at picking, whether product can be over-received against a PO, and the movement paths product takes through the warehouse during the order fulfillment process. All configuration changes are to be logged by the order-fulfillment systemindicating when the parameter was changed to allow for traceability to changes that might impact system performance. Where allowed by the customer and local/regional laws, the user that performed the change is also logged. In one embodiment, the control systemis “cloud based” and provides instructions and information. Such as, where to send workers, predicts capacity based on current information (in the warehouse/fulfillment center), alerts for operational risk, and suggests actions.

8 FIG.A 8 FIG.A 8 FIG.A 802 802 804 806 804 806 804 806 804 806 301 802 804 806 804 806 804 806 804 Workflows consist of a series of tasks (or steps) required to complete the workflow in which data is updated and transferred. Tasks can be designed to be performed by a specific type of machine or by a human. Tasks contain code that executes when a task is performed. The code consists of either a single microservice or a set of microservices that are designed to work together. For example, in an order identification task, an Order_ID is input to allocate inventory. In response, a corresponding output includes, for example, a list of inventory reservations for that order (location, SKU, quantity reserved); the original order is modified where lines extended with the location to do the pick from; and a return status (i.e., success or failure). The task/step logic includes those steps to be carried out in accordance with the microservice task (e.g., for the Order_ID task, for each order line, available inventory is found for that order line; the order line is updated with the location where the inventory is found; and an inventory reservation is created for that specific order).illustrates an example of a taskthat allocates inventory for an order. This taskconsists of two microservices,. Both of the microservices,call two code functions. For example, inventory microservicecalls exemplary operations [Inv_Info Get_Available_Inventory_for_SKU(SKU)] and [Inv_Res Create_Inventory_Reservation (Loc,sku,qty,order)], while inventory microservicecalls exemplary operations [Order_Get_Order_by_ID (Order_ID)] and [Void Update_Order_Line (OrderLine line)]. Each time this task is performed, these two microservices,(and their operations) will be executed. As illustrated in, when an order ID is received by the control system, the exemplary workflow's first task or step logic outputs a list of inventory reservations for that order (location, SKU, and quantity reserved), modifies the original order to extend the lines with location(s) to do the pick from, and returns a status (success/failure). The workflow's second task or step includes finding available inventory for each order line's SKU, updating the order line with the location where the inventory is found, and creating an inventory reservation for that specific order. As illustrated in, when the inventory allocation taskis called by the input of the order ID, a pair of microservices,(i.e., an inventory microserviceand an order microservice) are called to execute the workflow. As noted above, each microservice,includes a pair of code functions. The operations of the inventory microserviceinclude call functions for acquiring the information concerning the location, SKU, quantity, etc. of the order and reserving the inventory items for the order.

806 804 806 304 2 FIG.A Meanwhile, the operations of the order microserviceinclude call functions for calling the particular order according to its order ID and updating the order lines of the called order (with the location where inventory found). As discussed herein (and illustrated in), the microservices,used to execute the workflow are selected from a libraryof available microservices (e.g., a library of available APIs that can be used to build a desired function).

8 FIG.B 858 802 858 858 854 856 304 As illustrated in, microservices can be grouped together in a “wrapper microservice”. Taskscan execute these wrapper microservicesand, when executed, the wrapper microservicewill execute its sub-microservices,. This approach (wrapper microservices) allows for often-used functions that consist of multiple microservices to be easily inserted into tasks without having to recreate the function each time and allows for streamlined updates to microservices, as sub-microservices (in the microservices library) can be updated, which in turn updates all associated wrapper microservices.

858 802 802 858 802 858 854 856 854 856 854 856 854 856 854 856 304 8 FIG.B 8 FIG.A 8 FIG.A 8 FIG.A The wrapper microserviceof, similar to the taskof, includes an example of a taskthat allocates inventory for an order by calling the wrapper microservice. As discussed with respect toabove, in an exemplary order identification task, an Order_ID is input to allocate inventory. In response, a corresponding output includes, for example, a list of inventory reservations for that order (location, SKU, quantity reserved); the original order is modified where lines extended with the location to do the pick from; and a return status (i.e., success or failure). The task/step logic includes those steps to be carried out in accordance with the microservice task (e.g., for the Order_ID task, for each order line, available inventory is found for that order line; the order line is updated with the location where the inventory is found; and an inventory reservation is created for that specific order). In a similar fashion, the task/step logic includes those function calls for the steps to be completed (call inventory; allocation of microservice function to perform the task to perform the task/step). This taskconsists of a wrapper microservice(an inventory allocation microservice) that calls a pair of sub-microservices (an inventory sub-microserviceand an order sub-microservice). Similar to those seen in, each of the two sub-microservices,calls a pair of code functions. For example, inventory microservicecalls exemplary operations [Inv_Info Get_Available_Inventory_for_SKU(SKU)] and [Inv_Res Create_Inventory_Reservation (Loc,sku,qty,order)], while inventory microservicecalls exemplary operations [Order_Get_Order_by_ID(Order_ID)] and [Void Update_Order_Line (OrderLine line)]. The inventory sub-microserviceincludes call functions for acquiring an inventory (by SKU) for the order, and creating an inventory reservation (location, SKU, and quantity reserved for the order). Meanwhile, the order sub-microserviceincludes call functions for calling the particular order according to its order ID and updating the order lines of the called order (with the location where inventory found). As also discussed above, the sub-microservices,can be selected from a libraryof available sub-microservices.

300 An exemplary multi-channel order-fulfillment systemis flexibly scalable up and down using “plug-and-play” modules providing additional storage, configurable workstations, AMRs, and point solutions for additional workflows. Thus, additional capacity can be added with little, or no infrastructure changes required. To account for the large amount of potential automation solutions that a customer may want to incorporate into its fulfillment operations, exemplary embodiments provide an “automaton marketplace” consisting of pre-built integrations to numerous automation solutions (both hardware and software solutions) that can be enabled and added into a configurable workflow. Such pre-built integrations can be implemented as “plug-and-play” modules.

3 4 FIGS.and Modular storage—automated or manual storage options that may be added or removed over time (full systems or additional shelves). AMRs/AGVs for transportation and buffering. Picking workstations (robotic and manual), which could be separate or combined with sortation induction stations. Packing workstations (robotic and manual) including auto packing equipment Parcel shipping solutions. Automation islands that include interchangeability in fixed automation/mobile/human. These pre-built integrations (plug-and-play modules) can exist for many types of automation and software systems (see), including, but not limited to:

Flexibility is enabled through standardized microservices for subsystems allowing scalability and interchangeability, i.e., simplified and repeatable integration of any subsystem into the solution without requiring custom integrations (avoiding dependencies, reprogramming). That flexibility is further enhanced by providing a marketplace of pre-built integrations to various automation and software solutions, the effort, time, and cost of implementation is significantly decreased as there is no need to write code every time any flexible fulfillment facility wants to add a new automation solution. This approach also ensures standardization of interfaces across all customers' fulfillment facilities which simplifies the ongoing maintenance of the integrations and decreases the overall support effort.

10 FIG. 1070 1070 1070 302 1070 301 1070 Referring to, an exemplary modular infrastructure selection and task panelis illustrated. In one embodiment, the panelfunctions as a selection and task allocation panel accessed by an operator or manager for selection of infrastructure components and their functional task/service selection (as needed for order-fulfillment). In another embodiment, the panelfunctions as a selection and task monitoring/indicator panel illustrating the control system's dynamic selection and reconfiguration of infrastructure components needed for order-fulfillment based upon current warehouse order-fulfillment activities (as provided by the order-fulfillment control and monitoring system). That is, the selection of configurations (or reconfigurations) of individual workstations, storage modules of a modular storage system, and/or the selection of workflows from a library of workflows for current or anticipated warehouse operations, may be either performed by user interaction with the selection and task allocation panelor performed dynamically by the control system(with the panelfunctioning as a selection and task monitoring/indicator panel).

10 FIG. 10 FIG. 312 354 352 312 1012 312 1012 312 1012 312 1012 1012 312 1076 a g a c d e g d illustrates the allocation, configuration, and status of warehouse sub-systems, such as, storage modules of a storage system, AMRs, and workstations. As illustrated in, the status of a set of storage modulesis illustrated by an array of graphical buttons-. The storage modulesrepresented by graphical buttons-are depicted as currently allocated and storing inventory. The storage modulerepresented by graphical buttonis depicted as currently selected for allocation, while the storage modulesrepresented by graphical buttons-are depicted as deactivated. When the graphical buttonwas selected for allocation (of the corresponding storage module), the graphical buttonwas also selected to provide an indication of the type of storage module allocated (e.g., component of an ASRS storage system, or the like).

1054 354 1054 354 1054 354 1054 354 1072 354 1072 a g h i j l h i 10 FIG. The graphical buttons-ofdepict AMRsallocated for transportation and/or sorting duties (and other assignments). Graphical buttons-depict AMRsthat have been selected for allocation and tasking, while graphical buttons-depict AMRsthat are currently deactivated and awaiting allocation. When the graphical buttons-were selected for allocation (of the corresponding AMRs), the graphical buttonwas also selected to provide an indication of the type of service and/or function that the allocated AMRsare being configured to perform. The graphical buttoncan also be used to select or indicate the type of AMR in question.

1052 352 1072 354 1074 1052 352 1052 352 1052 352 1074 352 1074 a c d e f g d e 10 FIG. In a similar fashion, the graphical buttons-ofdepict configurable workstationsallocated for order fulfillment duties. The graphical buttonindicates the type of functional tasks/services the allocated AMRperforms (or is to perform), while the graphical buttonindicates the type of functional task/service that the allocated workstation is configured to perform (or will be configured to perform). Graphical buttons-depict configurable workstationsthat have been selected for allocation and tasking, while graphical buttons-depict configurable workstationsthat are currently deactivated and awaiting allocation. When the graphical buttons-were selected for allocation (of the corresponding configurable workstations), the graphical buttonwas also selected to provide an indication of the type of service and/or function that the allocated configurable workstationsare being configured to perform. The graphical buttoncan also be used to select or indicate the type of AMR in questions.

1072 1074 1076 1078 In addition to the AMR task selection panel, the workstation functional task/service selection panel, and the storage module allocation panel, an additional panelis used indicate or select additional order-fulfillment services that the infrastructure components are performing.

312 354 352 312 354 352 1078 In one embodiment, those infrastructure components (,,) that are indicated as deactivated and awaiting allocation are currently sitting in the local warehouse facility and awaiting allocation and configuration. In another embodiment, an additional graphical button could be used to indicate that storage modules, AMRs, and/or configurable workstationshave been ordered and are expected to be delivered to the warehouse environment and activated in due course. The panelmay also be used to indicate the time frame for delivery of the requested infrastructure components.

300 301 300 300 300 Accordingly, the exemplary multi-channel order-fulfillment systemincludes scalability to meet fluctuating and seasonal demands, and they handle average to peak volumes. The flexibility is able to change over time, adapt cost efficiently and fast as the fulfillment operations grow or business needs change. With modular components and an adaptable control system (facility orchestrator), an exemplary order-fulfillment systemmay be flexibly managed and monitored (e.g., real-time data can be provided to advise operators and managers of current performance). Thus, the multi-channel order-fulfillment systemcan quickly and easily adapt without having to customize or redesign. Easy integration of flexible automation allows for quick scaling (up or down). Fully automated modules may be used to (gradually) replace human operators to reduce labor dependency. The resulting multi-channel order-fulfillment systemis not dependent on a specific unit of measure or workflow and allows non-linear workflows. The exemplary fulfillment facility's flexibility meets changing operational needs and thereby maximizes productivity, throughput, and capacity at low cost. Workflows are adaptable to handle dynamic operational needs and requirements as they occur. Dynamic resequencing of units is also possible to meet ever changing order backlog priority changes. Customers (fulfillment facilities) are allowed to build and modify operation workflows without needing to involve technical resources and without writing code to change (their workflows) using microservices (e.g., APIs) selected by the customer from a library of available microservices.

Changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the present invention which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.